Electrical Safety
ESWP and NFPA 70E
Electrical Safe Work Practice
1
Contact Info:
Faith Technologies, Inc.
PO Box 627
Appleton, WI 54944
800-274-2345 ext. 6513
brian.downie@faithtechnologies.com
www.faithERM.com
2
Today’s Goals:(Electrical Safety Awareness)
Discuss new NFPA 70E Code Release
Discuss Class Needs on Information You Feel
is Needed to Take Back With You.
We Will Define Electrical Safe Work Practices!
New Code Definitions for Qualified Staff?
Review of PPE Labeling Content and What it
Means for Your Staff
Review OSHA ties, Liability and NFPA 70E
Break Out Sessions as Time Permits
Review Safety Goals and PPE Discussions
Cover OSHA Interpretations and Links with
Sub Part S 331-335.
3
2015 NFPA 70E Discussions
The new 2015 code has been released. What do we
notice in this code cycle?
− No change in definitions of what constitutes a good PPE labeling
format (Again Wide Open), so it is important to maintain what the
employer expects to see on effective PPE labeling content, and in
many ways stick to your own path on format and structure when it
meets an OSHA Sub Part S expectation!
− Code committee has eliminated the prohibited shock boundary
requirement on labels.
− Code committee has eliminated hazard category 0 on a technicality
stating that arc flash hazards at or below 1.2 cal/cm2 technically
don’t pose an arc flash hazard, therefore it should not be classified
as a “hazard”
− Changes in wording with training and AED use.
− Changes in task based approach to PPE tables 130.
− Never lose sight of how OSHA views compliance!
4
What Do We Normally See With Companies
Implementing NFPA 70E Programs?
It takes time to change the culture with both Management
and site staff when implementing ESWP goals (Normally
two years is the average)
Support and continual reinforcement of goals with safety
is vital. Encourage employees to ask questions and ask
for their inputs.
Realize there are few perfect answers in many cases with
ESWP but the key topic is to always focus on some simple
aspects with electricity which is “How do we work on
equipment in a safe condition?”
5
Work Involving Electrical Hazards:
So, we are here today to examine NFPA 70E, OSHA
expectations and company policies right?
What should every conversation start out like when you
discuss ESWP with an employee at your facility when a
question comes up?
Common Questioning Format:
What are the task/s being performed by the employee?
Can these tasks be performed in a de-energized condition?
If Yes, then what is still required for PPE to confirm absence of
power has been achieved and do our employees know how to
do this correctly? Have they proven demonstrated skills?
If No, then what is our justification for why work has to be
performed while the equipment is energized and our attention
turns to filling out work permits!
OSHA allows very few excuses to work LIVE….
6
What do we Know From the OSHA
Perspective When we Evaluate NFPA 70E?:
Their focus is and has always been aimed at the
overall topic of:
Electrical Safe Work Practice!
What does that statement mean? Does this mean that we only
focus on the “arc flash” topic or does this mean as leaders in
safety we have to evaluate the entire topic and all hazards that
employees are facing? Policies, PPE programs, Site Specific
Programs in Place, Training, Qualification Needs etc…
Very seldom do we see OSHA reference NFPA 70E as they
have enough ammo in Sub Part S 331-335 to choke a horse
with if they want to find codes to reference for citations.
7
Most Frequently Cited OSHA Standards 2013:
1.
2.
3.
4.
5.
Fall protection, construction (29 CFR 1926.501)
Hazard communication standard, general industry (29 CFR 1910.1200)
Scaffolding, general requirements, construction (29 CFR 1926.451)
Respiratory protection, general industry (29 CFR 1910.134)
Electrical, wiring methods, components and equipment, general industry
(29 CFR 1910.305)
6. Powered industrial trucks, general industry (29 CFR 1910.178)
7. Ladders, construction (29 CFR 1926.1053)
8. Control of hazardous energy (lockout/tag out), general industry (29 CFR
1910.147) In the Midwest this is #1
9. Electrical systems design, general requirements, general industry (29 CFR
1910.303)
10.Machine guarding general requirements, general industry (29 CFR
1910.212)
8
New NFPA 70E 2015 Edition:
• OSHA Can Refer to 70E for Additional Information if
Needed But Rarely Do They Need To!
− Upon review of this new standard we recommend strongly that all
employers simply reference the standard to judge your safety needs
and plans vs what 70E may indicate.
− The struggle we have in any consensus code is they are often written
too openly and loaded with interpretation angles.
− Remember, OSHA has to demonstrate a risk/hazard to the employee in
order for any conversation to take place.
− Almost all citations circle back to Sub Part S 331-335 within the OSHA
circles.
− Citation totals in 2014 exceeded $10.3M between LOTO & ESWP
references. This has gone up each of the past three years and
continues to be a very easy topic.
9
We “Don’t Know What We Don’t Know”!
• Employee used wasp
spray on an exterior
bus. Wasps died along
with major injuries to
the employee when the
bus faulted.
10
Should We Believe in “Common Sense”?
Does everyone
have the same
history or
experience with
electrical
systems?
11
Qualified Employees?
12
Are we Ever Really Sure what is Behind Closed
Doors? Constant Awareness of Electrical Risks.
13
What is Arc Flash? Which Electrical Hazard is
Most Significant to Our Staff? Shock or Flash?
• An arc flash event can be described as the
release of heat energy, blast energy and
projectiles that can injure employees when
electrical equipment experiences a fault or
failure.
• Shock hazards are still our main concern! 4
to 1 over arc flash incidents so maintain
focus on electrocution prevention and glove
use!
• Daily, 6-10 major incidents occur Nationally!
14
What is Arc Flash? Which Electrical Hazard is
Most Significant to Our Staff? Shock or Flash?
15
Rack-In Incident
16
Typical Incident Exposure:
17
IEEE 1584.1 New Standard
• Both NFPA and OSHA Rely on IEEE for their Technical
Knowledge in the Engineering topic:
− Upon review of this new standard we recommend if you need to draft a
plan for NFPA 70E assessments, do not use this document as your
only resource, and again is important to focus your attention with OSHA
Sub Part S 301-335 standards as your focal point!
• IEEE and most people we encounter Nationally will automatically lean
towards the engineering aspects of the “arc-flash study”.
• This standard makes many references to “data-collection” and it is clear
that the owner (You as the Employer) hold the accountability based on what
you accept in scope.
• Do not assume any resource you find will take on any roles with LOTO
confirmations. Remember many of us fight with costs and juggling that
battle internally with upper management? This takes time to do correctly
with plant systems confirmation & LOTO.
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IEEE 1584.1 Standards on Arc Flash Studies
• Assumptions will be the end of us all!:
− 5.1 – Determination of which party(s) is to be responsible for
verification of one-lines, creating one-lines, and other site
data collection must be determined prior to the quoting of
the arc-flash hazard study.
− If the facility owner does not provide data to the engineer,
the owner should provide qualified personnel to guide those
responsible for the site data collection and assist as
required.
− Should you be cautious of these concepts in
consideration of LOTO value for equipment labeling at
the end of a standard engineering study?
19
IEEE 1584.1 Topic of Electrical One-Lines
• A Functional Electrical Drawing is the Backbone of
your ESWP Program!
• IEEE also has no good definition of the electrical one-line
diagrams.
They do say one-lines offer the best source of
management for your electrical management needs
but fail to define a good one-line or how that process
should take place.
Most programs Nationally we have seen since 2005
rely entirely on Engineering Software systems only.
Those normally fail to support day to day use and
are far too vanilla in nature.
20
NEC 110.24 Fault Current Markings on Equipment:
Article 110 –Requirements for Electrical Installations 110.24
Available Fault Current
(A)Field Marking.
1.Service equipment in other than dwelling units shall be
legibly marked in the field with the maximum available fault
current.
2.110.24A added compliance with 110.9 & 110.10. The
maximum available fault current is not intended to be used for
incident energy analysis!
21
2014 NEC 110.16 Arc-Flash Warning:
Article 110.16
1.The words “or factory” and “switchgear” have been added
to this requirement. The revision clarifies that the marking
applies also to switchgear, and it can be either field applied
or factory applied. (Be cautious of Contractors or
Electrical Inspectors forcing this issue)
2.The words “meet the requirements in 110.21(B)” have
been added to guide design structures of labels.
3.If labeling is applied at your site by outside sources
and you don’t have an effective program in place to
address ESWP, it might put you in a state of compliance
issue with OSHA.
22
2014 NEC 110.26(C)(3) Personnel Doors:
Article 110.26(C)(3)
The value “1,200 Amps has been lowered to 800Amps”
expanding requirements for panic hardware on egress doors.
The words panic bars, pressure plates, or other devices that
are normally latched but open under simple pressure have
been replaced with “listed panic hardware”.
23
2015 NFPA 70E 110.2(C)2:
(2) First, Aid, Emergency
Response, and Resuscitation.
The new code book has revised
wording in this section!
It used to read as defined below:
24
110.3 Host and Contract Employer Responsibility:
This is becoming a very easy target for OSHA compliance.
Rarely do we take the time to document what outside
contractors are on site to do for us.
25
110.2 Training Requirements.
(A) Training Requirements
The training requirements contained in this section shall apply
to employees exposed to an electrical hazard when the risk
associated with that hazard is not reduced to a safe level by
the applicable electrical installation requirements. Such
employees shall be trained to understand the specific
hazards associated with electrical energy.
(B)- The training required by this section shall be classroom
or on the job or a combination of the two. The type and
extent of the training provided shall be determined by the risk
to the employee.
• The 2015 NFPA 70E code requires evidence of the content of your training
and has added a dedicated section on First Aid, Emergency Response, and
Resuscitation.
• Focus on skills demonstration concepts of training programs! The “Show
Me” concept for in house training is what OSHA is seeking.
26
Article 110.2 Training Requirements
110.2 1 (a) Qualified Person:
D1(b)(4):
Persons permitted to work within the limited approach
boundary shall, at a minimum, be additionally trained in
all of the following:
a. Perform the job safety planning
b. Identify electrical hazards
c. Assess the associated risks
d. Select the appropriate risk control methods from
the hierarchy of controls identified in 110.1G,
including personal protective equipment
27
Article 110.1G Risk Assessment Procedure
110.1 (G):
Risk Assessment Procedure:
Informational Note: The hierarchy of risk control
methods specified in ANSI/AIHA Z10, American National
Standard for Occupational Health and Safety
Management Systems, is as follows:
1. Elimination
2. Substitution
3. Engineering Controls
4. Awareness
5. Administrative Controls
6. PPE
28
Article 110.2 Training Requirements
110.2 D Qualified Person:
(1) Qualified Person:
(c) An employee who is undergoing on-the-job training
for the purpose of obtaining the skills and knowledge
necessary to be considered a qualified person and who
in the course of such training demonstrates an ability to
perform specific duties safely at his or her level or
training and who is under the direct supervision of a
qualified person shall be considered to be a qualified
person for the performance of those specific duties.
29
Connecting OSHA & NFPA 70E - LOTO
30
Article 408.4 NEC Code Field Identification
Required
(B) Source of Supply:
All switchboards and panel boards supplied by a feeder in other than
one-or two-family dwellings shall be marked to indicate the device or
equipment where the power supply originates.
This code doesn’t read very well but the intent here is to get involved
with electrical work done in your facilities.
Electrical Contractors and Maintenance Staff alike are not overly
creative on labeling and often we don’t think in terms of LOTO
needs!!!!!
Common General Labeling
Lacking Good Upstream
LOTO information.
31
Article 130.2(A)(4) Normal Operation
Maintenance:
Define “Normal
Operation”? What is
clear, is the code is
expressing the need to
make sure we address
Maintenance of
equipment to ensure
we realize the ties
between risk levels
and equipment
condition.
32
Article 130.2(A)(4) Normal Operation (Cont:)
This New Code Article Will Inevitably Bring Up the Age Old
Question of “Closed Door Switching PPE Needs”:
Some people interpret closed door switching of breaker or
disconnects as if we should dress up to the same PPE levels
as determined by “OPEN” door levels
Others have united with a somewhat universal “Best Practice”
scenario of what represents a reasonable approach to this
topic.
OSHA and NFPA 70E are unable to truly define what our
exact exposure levels may be and to what extent covers can
contain faults but an employer can only be held accountable to
defined expectations of risk.
33
Article 130.2(A)(4) Normal Operation (Cont:)
This Article Will Inevitably Bring Up the Age Old Question of
“Closed Door Switching PPE Needs”:
Here is what has commonly been used to define closed door
risk management and PPE needs.
For known (calculated) HRC Levels of 0, 1 or 2
Recommended HRC Level 0 PPE for switching procedures
For known (calculated) HRC Levels of 3, 4 or Dangerous
Recommended HRC Level 2 PPE for switching procedures
Remember the maintenance component discussed
earlier and work with employees to understand the
importance of shedding load on a system before we
re-engage breaker disconnects.
34
Evaluating NFPA 70E Interpretations:
35
How Faults Can Carry Between Sections:
Enclosure:
Note: When you consider electrical exposure you must
consider the entire enclosure. Article 130.2 (2)
36
Article 130 Work Involving Electrical Hazards:
130.2 Electrically Safe Working Conditions
Energized electrical conductors and circuit parts shall be put
into an electrically safe work condition before an employee
performs work if any of the following conditions exist:
1. The employee is within the Limited Approach Boundary
2. **The employee interacts with equipment where
conductors or circuit parts are not exposed, but an
increased likelihood of injury from an exposure to an
arc flash hazard exists
Note: Our struggle with interpretation on definitions with enclosures
and what constitutes an “electrically safe enclosure” is the real issue
with cabinet designs and engineering arc flash ratings to the
enclosures. Normal construction methods and OEM’s alike are not
accustomed to these new concepts with installations.
37
IEEE 1584 Statements:
There are no good defined statements in the OSHA circles to rely
on but between NFPA 70E article 130.2 and IEEE comments above,
both are saying that we can’t rely on the breaker alone to lower
downstream energy levels if we have no isolation/separation of
equipment sections. Arc Flash ratings then apply to the entire
enclosures!!
©Faith Technologies, Inc.
38
The “New-Normal” Installation Method:
Danger!!!
HRC #1
©Faith Technologies, Inc.
39
Customer made a
decision to separate
the new service
sections. The
resulting arc flash
outcome was a
dangerous no live
entry on the left
incoming section
and a HRC 1 on the
right load center.
No compliance
interpretation issues
are possible in this
installation concept!
130.5 (D)Equipment Labeling Codes for 2015
Edition: (Arc Flash Portion) D(3)
Employers are being
confused by this first
portion of article 130.5
and vendors nationally
are not helping the
cause!
At least one of the following:
− Available incident energy and
the corresponding working distance,
or the arc flash PPE category in table
130.7(C)(15)(A)(b) or table 130.7(C)(15)(B) for the
equipment, but not both.
− Minimum arc rating of clothing
− Site-Specific level of PPE
40
130.5 (D)Equipment Labeling Codes for 2015
Edition: (Cont)
(1) Nominal system voltage
(2) Arc flash boundary
•
Exception: Labels applied prior to
September 30, 2011
are acceptable if they contain the
available incident energy or required
level of PPE. (This exception reads
poorly)
41
130.5 (D)Equipment Labeling Codes for 2015
Edition: (Cont)
Liability Statements on Equipment Labeling!!!!:
The method of calculating and the data to
support the information for the label shall be
documented.
Where the review of the arc flash hazard risk
assessment identifies a change that renders
the label inaccurate, the label shall be updated.
The owner of the electrical equipment shall be
responsible for documentation, installation,
and maintenance of the field marked label.
42
Overview of Informative 2015 PPE Label Format:
Complete Statements in
PPE listings
Shows When Gloves
are needed. Prohibited Approach
Boundary was eliminated for 2015
Supports Electrical
LOTO Needs
Date Optional for 70E
Shows Fault Current Levels to Aid in Breaker Applications
43
Minimum AR PPE Content For Labels:
44
Category
Required Protection FR Clothing
Category 0*
Untreated Cotton Long Sleeve Shirt,
Pants, Safety Glasses, Hearing
Protection
Category 1
AR Shirt, AR Pants, Hard Hat, 4
cal/cm2 Face Shield, Safety Glasses,
Hearing Protection
Category 2
AR Shirt, AR Pants, Hard Hat,
Balaclava/Hood, 8 cal/cm2 Face
Shield, Safety Glasses, Hearing
Protection
Category 3
AR Shirt & Pant + AR Coverall,
Switching Hood, Safety Glasses,
Hearing Protection
Category 4
AR Shirt & Pant + AR Coverall,
Double Layer Switching Coat and
Hood, Safety Glasses, Hearing
Protection
2015 Code no longer
formally recognizes Category 0
as an “Arc Flash” Category
*The need for natural fibered garments
and general PPE however has not
changed!!
2015 PPE Category 0 Clarification:
Clarification on Category 0:
The NFPA Code based on a technical
evaluation of incident energy
exposures to the body has eliminated
“Category 0” from table 130.7(C)(16).
This shift in clarification was an
attempt to use the code tables to
define “actual” arc flash levels so the
code felt that having a category in the
tables for level “0” was not needed.
We as employers are still required to
post a PPE label however and still
required to inform staff of what clothing
and general PPE is required to be
Note: (*) While the 2015 NFPA 70E Edition no longer
used.
This PPE label represents Faith
45
Technologies official position on
recommended PPE label formats on
exposure levels 1.2cal/cm2 or less.
recognizes Category 0 as an “arc flash” hazard, the
need for proper personal protective equipment
(PPE) remains unchanged.
Incomplete Label?? Is This Still Correct per NFPA
70E Code?? (Yes) But….
Many PPE label formats
don’t fully disclose
valuable PPE
Information
Protective Device Names will often not represent true LOTO points in a system
so be careful on what you reference here..
46
Connecting OSHA & NFPA 70E – PPE Labeling
©Faith Technologies, Inc.
47
130.7C16 New Protective Clothing and PPE
Equipment Table
Table 130.7(C)(16) Protective Clothing and Personal Protective Equipment (PPE)
• Remember this table no longer defines PPE Category 0
however we are still enforcing the minimal PPE expectations
on labeling such as Cotton Clothing, Safety Glasses and
hearing protection etc.!
48
New 2015 Task Based Table:
49
New 2015 Table to Define Parameters:
50
Skills Sheet:
• Training for qualified
employee status is
largely based on the
concepts of “show me”.
• In summary, we can have
great safety policies and
good equipment labeling
in place BUT if
employees do not
demonstrate effective
practice of our safety
needs, this represents a
problem with
compliance.
51
Obtaining a De-Energized State Correctly is our
Primary Goal with ESWP and NFPA 70E:
De-Energized Work Practices
(Supportive PPE Labeling/Process)
This example shows a standard
disconnect with ideal labeling in place
which in turn supports the fundamental
goal for any safety program.
If an employee was asked this question,
how would they be able to respond now?
OSHA Question: If you had to
change a fuse in this
disconnect, explain to me how
you would do that?
52
130.2 Electrically Safe Working Conditions:
130.2(B)(1): Energized Work Permit.
(1) When Required.
When energized work is permitted in accordance with
130.2(A), an energized work permit shall be required
under the following conditions.
1. When work is performed within the restricted
approach boundary.
2. When the employee interacts with the
equipment when conductors or circuit parts
are not exposed but an increased likelihood of
injury from an exposure to an arc flash hazard
exits.
This reads very similar to 130.2!! The only
difference is in #1 where they reference limited vs.
restricted boundaries.
53
130.2 Electrically Safe Working Conditions:
130.2(B)(3): Energized Work Permit.
(3) Exemptions to Work Permit.
An energized work permit shall not be required if a qualified
person is provided with and uses appropriate safe work
practices and PPE in accordance with Chapter 1 under any
of the following conditions.
1. Testing, troubleshooting, and voltage measuring.
2. Thermography and visual inspections if the restricted
approach boundary is not crossed
3. Access to and egress from an area with energized electrical
equipment if no electrical work is performed and the restricted
approach boundary is not crossed
4. General housekeeping and miscellaneous non-electrical tasks
if the restricted approach boundary is not crossed.
54
What Constitutes Valid Reasons to Work on
Energized Equipment??
1. Additional hazards or Increased risk: Employer must
demonstrate that de-energizing introduces additional hazards
or increased risks to the employee.
2. Infeasibility: Employer must demonstrate that the task to be
performed is infeasible in a de-energized state due to the
equipment design or operational limitations. (Be very cautious
of discussing costs or money in any way if you chose to use
this)
3. Less than 50 volts: Self explanatory…
55
Work Permit Break Out Session:
This break out session is challenging but brings up great
discussions!
Many of you won’t support any energized work as a rule but
there may come a day when one of these meetings does
happen and are you prepared to fill one of these out?
As groups of two or three, role play to fill out the work permit
the best you can.
The person who is doing the work fills out the permit
The person responsible for authorization (Safety) would be
the one who signs off on the permit or denies the permit!!
56
WORK PERMIT EXAMPLE:
Your goal is to use the
work permit sheet to
discuss a project you have
in mind.
Be Creative and…
BE REALISTIC on what
you likely have taking
place in some instances
now.
It is more important to
learn how to fill these out
and what they mean so
you can help others and
also manage contractors!
57
Required Meter Safety Items
Double check your
meter to ensure it
is current
Please make sure your meter leads are correct
58
Voltage Testing Represents our Greatest Daily
Exposures!
Incorrect fuse used in multi-meter
59
Not Approved!
Look for this symbol to
indicate approved tools
but be careful the tool is
still ASTM registered:
(Hint: these tools don’t have it!)
60
60
Study of Electrocutions
12
16
6
15
25
110-120V
220-240V
277V
440-480V
600V
Frequencies of Electrocution Incidents
Identified by FACE
61
By Low Voltage Level (<600 Volts), 1982-1994
Defining One-Line Diagrams?? What do we Look
For?:
• One-Line Diagrams are the building
FED FROM
UTILITY
blocks for sound electrical safety
programs including project
discussions and safe work
practices!
XFMR-MDP-3
645051A6
E SIDE OF BLDG
Y
2500 KVA
PRI 12,470V
SEC 480V
5.77% Z
3Ø
60'
TRAY
(6) 500KCMIL THHN
(2) 500KCMIL NEUT
MDP-3-MAIN
480V
800A
3Ø
30K AIC
INST = MAX
LA36800
SQ-D
MDP-3-2
MDP-3
480 VOLTS
38.8 KA SYM RMS
134.64 CAL/CM^2
Dangerous!
MDP-3
ENGINE RM 1
SQ-D, HCWM
480V, 3Ø
MDP-3-4
480V
90A
3Ø
18K AIC
FA36090
SQ-D
FC34100
SQ-D
480V
100A
3Ø
65K AIC
215'
1-1/4" EMT
(3) #4 THHN
MDP-3-5
480V
400A
3Ø
30K AIC
INST = MAX
LA36400
SQ-D
215'
1-1/4" EMT
(3) #3 THHN
XFMR-7
ABOVE
LINE 1 FREEZER
Y
ABOVE
LINE 1 FREEZER
3Ø
Y
75 KVA
PRI 480V
SEC 240V
5.8% Z
3Ø
90'
2-1/2" EMT
(3) 4/0 THHN
(1) 4/0 NEUT
LPNL-21-MAIN
240V
225A
3Ø
10K AIC
Q2L3225
SQ-D
LPNL-21-1,3,5
LPNL-21
LINE 2&3 HALLWAY
SQ-D, NQOD
120/240V, 225A, 3Ø
42 CKTS, 0 SPACES, 0 SPARES
240V
70A
3Ø
10K AIC
QO3070
SQ-D
DSC-RC-3
480V
400A
3Ø
30K AIC
INST = HI
(4000A)
LAL36400
SQ-D
ENGINE RM 1
DSC-RC-3
480 VOLTS
23.9 KA SYM RMS
0.78 CAL/CM^2
Category 0
90'
2-1/2" EMT
(3) 4/0 THHN
(1) 4/0 NEUT
LPNL-21
240 VOLTS
1.2 CAL/CM^2
Category 0
LPNL-21-2,4,6
75T6H
SQ-D
ABOVE
LINE 1 FREEZER
Y
75 KVA
PRI 480V
SEC 240V
5.8% Z
3Ø
50'
2" EMT
(3) 3/0 THHN
(1) #4 NEUT
LPNL-L6B
Q2L3225
SQ-D
LINE 2&3
HALLWAY 225A MAIN
120/240V
225A
3Ø
10K AIC
42 CKTS
0 SPACES
3 SPARES
480V
CPNL-RC-3
FVNR
SIZE 6
SQ-D
ENGINE RM 1
B3.30
CPNL-RC-3
480 VOLTS
23.5 KA SYM RMS
0.77 CAL/CM^2
Category 0
LPNL-22
240 VOLTS
1.2 CAL/CM^2
Category 0
270'
1-1/4" IMC
(3) #8 THHN
(1) #8 NEUT
210'
1-1/4" EMT
(3) #3 THHN
5'
2" EMT
(6) 3/0 THHN
(2) #2 GND
LPNL-22
240V
20A
3Ø
10K AIC
QO3020
SQ-D
480V
100A
3Ø
18K AIC
XFMR-5
75T6HCT
75 KVA
PRI 480V
SEC 240V
FA34100
SQ-D
125'
2" EMT
(6) 3/0 THHN
(2) #2 GND
XFMR-6
75T6HCT
SQ-D
MDP-3-8
QBL32225
SQ-D
ABOVE LINE 1
FREEZER
225A MAIN
120/240V
225A
3Ø
10K AIC
42 CKTS
0 SPACES
3 SPARES
LPNL-L6B
240 VOLTS
1.2 CAL/CM^2
Category 0
LPNL-23
QO20
SQ-D
LINE 3 MEZZ
M
120/240V
PUMP
3Ø
LPNL-23
240 VOLTS
1.2 CAL/CM^2
Category 0
62
M
LIFT RAV RM
MISCELLANEOUS
120/240V
SMALL LOADS
250 HP
480V
3Ø
REFRIGERATION
COMPRESSOR 3
MISCELLANEOUS
120/240V
SMALL LOADS
It is important to realize that in an
engineering study, the “data collection” in the field
is simply taken using existing equipment naming and
is re-entered in software programs back at the office.
Educate your clients that these types of one-lines are
not descriptive nor complete for LOTO use and
their staff will not prefer to work with them.
Normally they are not received well by OSHA.
63
Value Based Engineering Reports: Seek Simplicity
and Universal Ties with your One-Line Diagrams.
Table #1
Arc Flash Mitigation Table
Item #
1
2
3
64
Location
(Sheet #)
TURBSWGR
(E-002)
Protective
Device
Initial Setting
or Device
CO-6 Relay set
GEN-1, GENat: 1200A,
2 & RESERTap=5.0,
SWGR-CABTime=4.0, GEN1B
1 and GEN-2
CP-44-PKRShawmut type
B
CP-44-PKR AJT 250 amp
(E-101)
fuses
CP-45A-1
(E-109)
MCC-Z45C6E
Sq-D 60 amp
breaker
Present
Cal/cm^2
Hazard Class
Recommended
Change
New
Cal/cm^2
Hazard
Class
49
Dangerous!
Remove utility feed
at RESERVIORSWGR-CAB-1B
10
3
1
Replace CP-44PKR
fuses with
Bussmann type
LPS-RK 250 amp
fuses
0.44
0
1
Install a fused
disconnect before
CP-45A-1 using
Bussmann type
LPS-RK 60 amp
fuses
0.05
0
1.7
3.3
2015 Additions for Maintenance
• 205.3 General Maintenance Requirements:
Electrical equipment shall be maintained in
accordance with manufacturers’ instructions or
industry consensus standards to reduce the
risk associated with failure. The equipment
owner or the owner’s designated representative
shall be responsible for the maintenance of the
electrical equipment and documentation.
65
205.3 General Maintenance Recommendations
• 205.3 General Maintenance Requirements:
Commonly, many companies focus primary attention on
breakers or loads 400 amps or larger considering smaller
loads are common or considered “off the shelf” items.
Focus on some “high maintenance” items or those
equipment types that may pose a greater level of
maintenance such as bolted pressure switches. These
types of equipment have many moving parts and require
special lubricants and exercising regularly.
66
Know How to Read Arc Flash Scope Content:
• #1 Assumption made with 90% of all Arc Flash
Studies we see Nationally Today: (Direct word
quotes):
− Field Technicians will visit your facility to collect the
necessary electrical data to perform an Arc Flash Hazard
Analysis. Who in this room can define what “Data
Collection” means?
− Direct Quote: “Your facility’s panel boards, bus ducts,
motor control centers, disconnects, switchgear, etc,
should be properly labeled per the National Electrical
Code prior to our arrival.” What does this imply?
67
You will go back to your Plant:
(Need Three Volunteers).
• Safety Director to maintenance electrician
−“ I just learned about arc flash and blast, it
scared the bleep out of me.”
−“Do you work energized?”
• Electrician to Safety director
−“I always turn it off”
−Safety Director response: Thank You!!
68
68
Now we have an OSHA inspection
• CSHO to safety director
• What do you have for an ESWP program?
• Safety Director to CSHO- “We never work
energized we lock it out all the time”.
• CSHO to SD That’s good, well let’s get started
and go out to do the walk around inspection of
your facility.
69
69
CSHO to Maintenance Electrician
• What kind of testing devices do you have?
• Electrician to CSHO , I have an ammeter,
phase tester, a Volt Ohm Meter (VOM) from
*****, a solenoid tester, an electrical field
tester, and a few others.
• CSHO - What do you have to for PPE?
• Electrician to CSHO, Safety glasses and a
hard hat with muffs
• CSHO response….HMMMMMMMMMM??
70
70
CSHO to Maint Electrician
• CSHO How old is this place?
• CSHO What kind of a system do you have to
maintain?
• Sparky to CSHO - This place is 40 years old
and we have added a lot of new equipment.
The only new stuff is the buss bar on the new
line.
• CSHO, do you have any of those old 70s
breakers?
• Sparky yes, We replace them when they fail.
71
71
CSHO to Maintenance Electrician
• Do you have a one line diagram?
• Sparky, somewhere I think
• So when you have to trouble shoot a problem
in this old plant what do you use.
• Sparky, I’ve been in this plant for 29 years.
• Any new guys like you?
• Sparky, yea Curly and Mo retired so they
hired Larry We are training him.
72
72
CSHO to Maintenance Electrician
• What is your up time goal?
• Sparky, 90%
• So when you troubleshoot and find the
problem, you always turn the power off?
• Sparky, Welllllllllll. Sometimes we can’t
• When can’t you?
• Sparky, The new line has one main
disconnect, that kills the program if you turn it
off. We did it once and the production
supervisor had a fit.
73
73
CSHO to Maintenance Electrician
• Any other times that you can’t turn it off?
• Sparky, No
• You mean you know where every thing is fed
from?
• Sparky, Welllllllllll, most of the time
• What about your new guy Larry
• Sparky, Oh he is just learning
• So he guesses??
74
74
CSHO to Maintenance Electrician
•Could I look in your tool box?
75
75
76
76
Electricians’ Tools
Electrical Tape as
Insulation
Gouge –
Weld Mark
77
77
CSHO to Maint Electrician
• So you do work energized,
• Your tools are not rated,
• You have no idea of the calorie levels to
which you are exposed,
• You have no arc PPE and you work hot
swapping buss plugs from a ladder.
• You don’t have any live work procedures.
• Sparky Yea, but I am careful!
78
78
CSHO to Safety Director
• You were made aware of Arc Flash and Blast
at ABC Company.
• You have ignored all of the hazards
• You will be receiving correspondence from us
in the future. Now let us discuss some
abatement dates.
79
79
OR
•You have the example of a VPP
company that did their homework, and
protected their people.
80
80
WOOD RIVER
Tuesday, Wood River experienced a
significant electrical arc flash incident
in one of the substations. … there
were ___injuries and it looks as
though they will have the substation
back in service in the next 3 or 4 days.
81
81
82
82
What does a new hood look like?
83
83
The Arc?
•They speculate that the initiating event
occurred when the metal edge on one of the
voltage meter probes touched the edge of the
grounded steel shutter.
•The arc occurred and……..
84
84
The Employee was Protected
•You can see in next slide how the hood
looked after being exposed to the arc
flash but what you can’t see is that the
inside of the hood looks like new. A few
years ago they upgraded their electrical
safe work practices and their electrical
PPE to state of the art gear
85
85
• PPE is Designed to Create Survivable Outcomes.
This PPE Did it’s Job!
86
86
Remember What the “Before” Looked Like?
87
87
The restricted approach
boundary for a 480 volt nominal
system is?
a.
b.
c.
d.
88
Not specified
1.07 m (3 ft 6 in.)
25.4 mm (0 ft 1in.)
304.8 mm (1 ft 0 in.)
The restricted approach
boundary for a 480 volt nominal
system is?
d. 304.8 mm (1 ft 0 in.)
89
True or False
Qualified persons shall be able
to show demonstrated skills in
order to be considered
qualified for working on or near
energized equipment?
90
True
Only qualified persons capable
of demonstrating the ability to
recognize and avoid electrical
hazards are allowed to interact
on systems of 50 volts or more.
91
What Might OSHA Look For?:
• Will look for PPE labeling
• Will seek inspection of tools and PPE use
• Will seek supporting data on training efforts to show
evidence of qualified staff
• Will seek evidence of the process used for risk
assessments (What was the written scope of work
for the arc flash process?)
• Will review and quantify your use of energized work
permits and job briefings
• Bottom Line, How do we manage de-energized work
methods
92
Ending Summary:
• The new 2015 NFPA 70E code book has some
interesting new revisions but don’t get distracted
from the basic fundamental goals of electrical safety
and your role as an employer!!! This code is not
written well and is very minimal in design.
− Focus on great equipment labeling (accurate) that
supports fundamental needs for “electrical LOTO”
goals!
− Focus on good informational One-Line Diagram
development that will help staff grow in LOTO and
safety planning needs!
− Get solid PPE labeling in place to make it clear to
your staff on their exposures
− Train & Keep Training Employees!
93
Ending Thoughts?:
• Questions??
94